Foam bedding

ABSTRACT

Foam resin bedding for use a box spring and mattress, both having areas of differential resistance to weight, the middle area having greater resistance than the end areas. This is accomplished in the box spring by forming on one side integral tapered protuberances extending normally from the face thereof, the protuberances in the midportion being smaller and closer spaced than those at the ends. In the mattress element the differential resistance is obtained by varying the size and or number of the pins extending through the foam body in the mold, as regards the midportion and end portions of the molded body.

United States Patent FOREIGN PATENTS [72] Inventor Billy P. Mims Oak Park, 370,544 8/1963 Switzerland 5/345 [21] pp 817,473 863,343 3/1961 Great Britain.. 5/345 Filed p 1969 1,324,907 12/1963 France 5/345 [45] Patented l 1971 978,951 1/1965 Great Britain.. 5/345 1 Assignee Sears. Roebuck and 1,440,2s4 4/1966 France 5/345 Chicago, Ill.

Pnmary ExammerPaul R. Gilliam Attorneys-Frank l-l Marks and Nathan N. Kraus [54] FOAM BEDDING l claim4nrawing Flgs' ABSTRACT: Foam resin bedding for use a box spring and [52] US. Cl 1. 5/345 mattress, both having areas of differential resistance to weight, [51 Int. Cl ..A47c 23/00, k h middle area having greater resistance h the end areas A476 25/00 This is accomplished in the box spring by forming on one side of Search X, integral tapered rotuberances extending normally from {he 361 X face thereof, the protuberances in the midportion being References Cited smaller and closer spaced than those at the ends. ln the mattress element the differential resistance is obtained by varying UNITED STATES PATENTS the size and or number of the pins extending through the foam 2,878,494 3/1959 Healy 5/345 body in the mold, as regards the midportion and end portions 3,394,414 7/1968 Unger 5/345 ofthe molded body.

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FOAM BEDDING My invention relates to bedding, and has to do more particularly with box springs and mattresses formed of foamed resinous material.

It has long been customary to provide such items in combination on a bed, the spring normally being disposed at the bottom and the mattress on top, the sheets, blankets, coverlets and the like being made" or arranged over the mattress.

BACKGROUND AND PRIOR ART For many years it was customary to provide a box spring containing a large number of coil springs secured within a fabric casing for resilient support of the mattress. The latter was usually a solid pack of hair, cotton-wool or similar material enclosed within a fabric casing or ticking.

Comparatively recently it has been proposed to employ for bedding a block of foamed resin, such as natural or artificial rubber, polyurethane or other synthetic resin. Such material has been found to have certain desirable qualities such as durability, resistance to packing and lumping, and the desired resilience.

Also, it has been recognized that the human body, because of its nonuniform weight distribution, rests more comfortably on a mattress wherein the resistance to body pressure is differentially disposed according to the weight variation in different parts of the body. That is to say, greater resistance is provided in the midportion of the mattress than in the end portions thereof. An example of prior art of this character is Robell U.S. Pat. No. 2,504,352 Apr. 18, 1950. Also ofinterest is Adler U.S. Pat. No. 3,083,380, Apr. 2, I963; Pollock U.S. Pat. No. 3,2l0,78l, Oct. 12, 1965, and Trogdon et al. U.S. Pat. No. 3,287,748, Nov. 29, 1966.

I am also aware that the prior art has proposed molded resilient cushions and the like wherein resilience is provided by a plurality of spaced protuberances projecting normally from one face of the molded body. Examples of such art are Berman U.S. Pat. No. 2,659,4l8, Nov. 17, 1953, and Unger U.S. Pat. No. 3,205,515, Sept. 14, 1965.

BRIEF OUTLINE OF THE INVENTION An object of my invention is to provide new and improved bedding of resilient resinous foam material which will have a number of advantages over products of this type heretofore known.

More particularly, one object of my invention is to provide a new and improved so-called box spring comprising a slab or block of foamed resinous material having differential areas of resistance, with greater resistance in its midportion, supporting the heavier parts of the human body, and less resistance in its end portions.

Another object is to provide an article of the class described characterized by a plurality of spaced protuberances on one face thereof, usually disposed on the bottom of the slab, said protuberances in the midportion of the slab being of such size and so spaced, as compared with the protuberances in the end portions of the slab, as to provide greater resistance, i.e. less resilience, in the midportion as compared with the end portions.

Still another object is to provide, in combination with a box spring of the type described, a mattress also comprising a slab of foamed resin, said mattress being characterized in that it is less resilient in the midportion thereof than in the end portions, said variations in resistance being accomplished by varying the size and number of voids in the midportion as compared with the end portions.

Still another object is to provide a combination of box spring and mattress having the characteristics hereinabove described Various other objects and advantages will doubtless suggest themselves to those skilled in the art as the description proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a combined perspective and longitudinal section DETAILED DESCRIPTION Reference character Mdesignates a mattress which comprises a slab or block of plastic foam, production of which is well known in the art. It may be molded or otherwise produced, preferably as a single unit, or in a plurality of sections, as desired. Said mattress will be covered in the usual way with a fabric ticking T.

Said mattress M comprises a plurality of sections, viz, a midsection 10, which may be approximately one-third of the mattress measured length wise. The other two sections, 10a and 10b which may likewise each constitute approximately one third of the unit, may be referred to as the end sections or the upper and lower sections,'respectively, again referring to the length of the mattress.

In order to provide maximum support and resistance where desired, namely to the heavier midportion of the sleepers body, midsection 10 will be of maximum density as compared with end sections 10:: and 10b. This objective may readily be accomplished by varying the size and number of the voids 12a, 12b formed within the foam.

These vertical passages or voids 12a, 12b are formed in the foam body by pins, usually present in the mold for thermal conduction in the curing operation, and usually of metal. While such pins have been so employed for some time, I believe I am the first to suggest varying the size thereof for the purpose here described.

I have found a density of about 33 pounds p.s.i. RMA (Rubber Manufacturing Association Test Standards) or a range of about 30 to 36 pounds RMA, to be satisfactory for midsection 10, while a density of about 28 pounds RMA, or a range between about 26 and 31 pounds, to be satisfactory for end sections 10a and 10b.

The slab constituting the mattress M may have a thickness of approximately 5% inches, more or less, it being understood that this dimension is not-critical. It will also be understood by those skilled in the art that such items as a quilted tranquilizer pad, etc., may be superimposed on the core M and attached thereto as by stitching; also, that the sides and ends may be finished in the usual manner, as with strips or slabs of foam material, ticking, etc.

Underlying the mattress or core M and corresponding to the usual box spring is a block or slab S, which may also be encased in fabric ticking. Said slab S will also vary longitudinally thereof to provide maximum resistance in the midsection 20, which may be roughly one-third of the length, the end sections 20a and 20b, each also approximately one-third of the length, providing less resistance than said midsection 20.

I preferably accomplish this differential in resistance by providing on the lower face of slab S a plurality of spaced protuberances 25 (FIG. 4). Said protuberances extend generally normally from the bottom face of slab S and are preferably of generally conical configuration, the apices of said protuberances being at the outer free ends thereof. Said protuberances may be arranged in any convenient or suitable manner, being preferably produced by suitable mechanical equipment or molds well known in the art.

In the embodiment shown the protuberances are arranged in staggered rows, as seen best in FIG. 4, but such arrangement is merely exemplary and is in no sense critical.

ln midsection the protuberances are relatively shorter than those in end sections 20a and 20b, are smaller in cross sectional area and more numerous than in the end sections, in order that said protuberances in midsection 20 may provide more resistance to the greater weight of the body midportions.

While I do not consider the dimension, arrangement or spacing of the protuberances 25 to be critical, it will be noted from FIG. 1 that in the end sections said protuberances may extend outwardly for a distance of from one-fifth to one-third of the overall thickness of the slab (including the protuberances), and are spaced apart a distance approximately equal to the median diameter of said protuberances; in midsection 20 said protuberances may extend outwardly approximately for a distance between one-sixth to one-eighth of the overall thickness of the slab.

ln the case of spring S, as in the core M, the physical character of the foam in the respective midand end sections may be essentially similar to the sections 10, 10a and 10b, respectively.

Spring S may likewise be encased in a fabric casing or ticking and be underlaid by an insulation board formed of corrugated fiber board, preferably of about 200 psi. test, under which may be arranged a hardwood panel 35.

The combination of bedding elements described above has been thoroughly tested and found to be highly satisfactory from the standpoint of comfort. The desired maximum firmness is provided where needed, under the heaviest portions of the sleepers body. Furthermore, products embodying my invention may be manufactured most economically by mass production methods at relatively low cost. Said products have great durability and may be used over a long period of time without deterioration. Because of ventilation means built into the structure, there is little or no tendency for the absorption of body odor.

Various changes coming within the spirit of my invention may suggest themselves to those skilled in the art; hence, I do not wish to be limited to the specific embodiment shown and described or uses mentioned, but intend the same to be merely exemplary, the scope of my invention being limited only by the appended claims.

lclaim:

1. In combination, a first bedding element and a second bedding element superposed on said first bedding element, said bedding elements each comprising a slab of substantial but minor thickness relative to its length and breadth and formed essentially of a resin foam, each of said elements having end portions and a middle portion with said middle portions generally underlying the midportion of the human body disposed thereon, said first element having a flat upper planar face and a plurality of generally conical protuberances projecting in a direction opposite from said face, the protuberances in the middle portion thereof being smaller and more closely spaced than the protuberances in the end portions and thus offering greater resistance to weight disposed thereon than the protuberances in the end portions, said second element having upper and lower flat planar faces and having a plurality of transverse vertical passages extending through its thickness, the passages being so varied as to size and number in the middle portion as compared to the end portions as to offer greater resistance to weight disposed thereon than in said end portions and a substantially rigid supporting panel underlying said first bedding element. 

1. In combination, a first bedding element and a second bedding element superposed on said first bedding element, said bedding elements each comprising a slab of substantial but minor thickness relative to its length and breadth and formed essentially of a resin foam, each of said elements having end portions and a middle portion with said middle portions generally underlying the midportion of the human body disposed thereon, said first element having a flat upper planar face and a plurality of generally conical protuberances projecting in a direction opposite from said face, the protuberances in the middle portion thereof being smaller and more closely spaced thaN the protuberances in the end portions and thus offering greater resistance to weight disposed thereon than the protuberances in the end portions, said second element having upper and lower flat planar faces and having a plurality of transverse vertical passages extending through its thickness, the passages being so varied as to size and number in the middle portion as compared to the end portions as to offer greater resistance to weight disposed thereon than in said end portions and a substantially rigid supporting panel underlying said first bedding element. 